Application Data Sheet

Transcription

1 Application Data Sheet Input Instruction

2 Table of Contents Notes... iii Application... 1 Type of Application... 1 Annual Usage... 1 Quantity per Release... 1 Estimated Budget... 1 Application Description... 1 Driver Information... 1 Type... 1 Quantity... 1 Horsepower... 1 Power Curve... 2 Speed... 2 Torque... 2 Mounting... 2 Axial Load... 3 Radial Load... 3 Shaft Configuration... 3 Direction of Rotation... 3 Gearbox Requirements... 3 Gearbox Type... 3 Ratio... 4 Spur/Helical/Bevel Gear Sets... 4 Planetary Gear Sets... 4 Output Torque... 5 Output RPM... 5 Increase/Decrease... 5 Drop In Replacement... 5 Duty Cycle... 5 B10 Bearing Life... 5 Input Configuration... 5 i

3 Output Configuration... 6 Axial Load... 6 Radial Load... 6 Clutch... 6 Flywheel... 6 Document Center of Gravity... 6 Center Distance... 6 Other Requirements... 6 Quality Requirements... 7 Warranty... 7 Welding... 7 Painting... 7 Testing... 7 Material Certifications... 7 Customer Witness... 7 Regulatory Specifications... 7 Approvals... 7 Service Factor... 7 Works Cited... 9 ii

4 Notes Open Application Data Sheet Form. To enter information, click on Click here to enter text and enter the information required for the question. For options that say Choose an item click on in, then click on the arrow to show list of possibilities and select the correct one. For a yes or no, CW or CCW question, simply click on the box next to the correct response to select that response. Figure 1: Screenshots of Data Sheet This form can also be printed and filled out by hand. Include as much information as possible. If you do NOT see Click here to enter text, Go to File->Options->Display and check Hidden text Figure 2: Screen Shot of Word options. iii

5 Application Type of Application Describe what type of gearbox is being requested. New: Requesting a design of a gearbox for a specific application. Existing: Requesting work for a gearbox that is currently owned. Redesign: Requesting a new design for a gearbox that is currently owned. Annual Usage Quantify how often the gearbox will be used in a year. Quantity per Release Quantify how many gearboxes are needed for the application. Estimated Budget Estimate how much the customer is looking to budget ($). Application Description Describe how the gearbox will be used. Include any information useful to the design of the gearbox. Including but not limited to: What is the use or purpose of the gearbox? Location of gearbox. Size limitations. Drawings. Driver Information Type Describe the type of input driver(s). Give as much detail as possible. Including but not limited to: Electric Motor Hydraulic Motor Gas/Diesel Engine Quantity Quantify how drivers (inputs) are used in this application. Horsepower Enter the horsepower of the driver. 1

6 Power Curve Attach a graph of the power curve. The power curve should look similar to the one shown below. If no power curve is given, PEM will assume 100% at the higher torque. Speed Quantify the speed or range of speed for the input driver (RPM). Torque Quantify the torque of the driver. Torque can be calculated from power and speed and vice versa. torque = Power speed hp 5252 lb ft = RPM 100hP lb ft = 1750RPM *5252 is a conversion factor when calculating using lb ft-hp-rpm. Conversion factor will be different if using different units. Mounting Describe how the driver is or will be mounted. Including but not limited to: Figure 3: Example power curve from a Baldor Electric Motor (Baldor Electric Company) Flanged: Driver mounted to the gearbox by a flange. (A) Foot mounted: Driver is mounted on feet. (B) Frame mounted: Driver is mounted at the base of the driver. (C) Figure 4: Motor mounting images. A, B, C from left to right. (ACP&D Limited) (Electric motors price India) (Transdrive Engineering Services Ltd) 2

7 Axial Load Quantify the axial load that will be applied to the output of the driver. Axial load is the load that is applied parallel to the shaft. (Figure 5) Figure 5: Shaft Loading (Igoe) Radial Load Quantify the radial load that will be applied to the output of the driver. Radial load is the load that is being applied perpendicular to the shaft. (Figure 5) Shaft Configuration Describe the configuration of the output shaft on the driver. Include as much information about the output as possible. Options include but are not limited to: Keyed Shaft Splined Shaft (male or female) Flanged Flywheel Length (Shaft and key-l) Width (key-w) Depth (key) Diameter of Shaft (d) Centerline distance to base d w Figure 6: Shaft with a key dimensions. (Pearson Education) l Direction of Rotation Check the direction of the driver. Clockwise Counterclockwise Bidirectional (able to rotate both directions). Figure 7: Rotation direction (Orientalmotor) Gearbox Requirements Gearbox Type Describe the type of gearbox needed for the application. Examples include but not limited to: Bevel Planetary Helical Worm 3

8 Ratio Spur/Helical/Bevel Gear Sets Calculate and quantify the desired ratio of the gearbox. (Input : Output) The ratio of the gearbox is calculated by taking each gear mesh and dividing the number of teeth on the output side gear over the number of teeth on the input side for each gear mesh and then multiplying all the meshes Example1: Gear 1: 50 Teeth Gear 2: 10 Teeth Gear 3: 45 Teeth Gear 4: 20 Teeth Gear 5: 37 Teeth Ratio = out in = N 2 N 4 N 5 = 10 N 1 N 3 N = = : 1 This means that for every turn the output makes the input turns of a rotation. Planetary Gear Sets Figure 8: Gear mesh example (Sowizral, Nadeau and Bailey) Sun Gear Ring Gear Planetary Gears Figure 9: Planetary Gear Example (GotTransmissions.com) Example 2: Sun Gear: 15 Teeth Planetary Gears: 5 Teeth Ring Gear: 50 Teeth Ratio = out in = Ring Gear Sun Gear + 1 = = 4.33: 1 4

9 Output Torque Quantify how much torque is needed at the output. (ratio_input : ratio_output) Output torque = input torque ratio_input Output RPM Quantify the speed at which the output shaft should rotate. (ratio_input : ratio_output) Output RPM = input RPM ratio_input Increase/Decrease Check if the gearbox is needed to increase or decrease the speed or torque. Drop In Replacement Check if the gearbox will be a drop in replacement for another gearbox. If so, describe all limitations and critical information describing the current gearbox. Duty Cycle Quantify the duty cycle of the desired gearbox. PEMs standard is: 100% power, 25% of the time 75% power, 50% of the time 50% power, 25% of the time Run at 4,000 hours B10 Bearing Life Quantify the bearing life required in hours. This is the life that is required of the bearings assuming that only 10% fail due to normal fatigue failure (90% reliability). If this is unknown, enter the desired life of the gearbox with (gearbox) following. Input Configuration Describe the configuration of the input shaft. (See Figure 6) Including but not limited to: Diameter of Shaft (d) Keyed Shaft Length (Shaft and key-l) Width (key-w) Depth (key) Splined Shaft (male or female) Flanged Flywheel Centerline distance to base 5

10 Output Configuration Describe the output shaft configuration. Including but not limited to: Diameter of Shaft (d) Keyed Shaft Length (Shaft and key-l) Width (key-w) Depth (key) Splined Shaft (male or female) Flanged Flywheel Centerline distance to base Axial Load Quantify the axial load that will be applied to the output of the gearbox. Axial load is the load that is being applied parallel to the shaft. (Figure 5) Radial Load Quantify the radial load that will be applied to the output of the gearbox. Radial load is the load that is being applied perpendicular to the shaft. (Figure 5) Clutch Check if a clutch is needed. Flywheel Check if a flywheel is needed. Document Center of Gravity Check if you would like PEM to calculate and document the center of gravity of the gearbox. Center Distance Quantify any center distance requirements for the input and output shafts. Other Requirements Describe any other requirements necessary for the application, including but not limited to: Ambient temperature (temperature of the gearbox surroundings) Vibration requirements Environment o Humidity o Corrosiveness o Dust 6

11 Quality Requirements Warranty Describe any desired warranty terms. PEMs standard warranty is 6 months. See website (listed in Works Cited) or Sales for details. (Power Engineering & Manufacturing, Ltd.) Welding Describe any welding requirements. If none are listed PEM will use the standard AWS D1.1 welding practices. Painting Describe any painting requirement, including but not limited to: Inside paint Outside paint Color Type of paint Testing Describe any testing requirements. Standard PEM testing includes a no load spin test until a constant temperature is achieved for 30 minutes. Material Certifications Describe any material certifications or requirements for the gearbox. PEM standard is 4140 Steel for shafts, 8620 Steel for gears when possible, 32 finish for bearings, and 16 finish for seals. Customer Witness Check if you will need someone to visit the shop to witness any part of the manufacturing or testing process. Regulatory Specifications Check in front of the box for any regulatory specifications, including but not limited to: ABS (Shipbuilding and Repair Quality Standards) AGMA (American Gear Manufacturers Association: Gear Quality) Military ISO (International Organization for Standardization: International Standards) Other: Give as much detail as possible Approvals Describe any approvals that are needed. Service Factor Quantify a service factor (factor of safety) for the gearbox. PEM will assume a service factor of approximately 1.35 or greater. 7

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13 Works Cited ACP&D Limited. "SLA Series - Three Phase Aluminum Induction Motors." n.d. ACP&D Limited. 17 September < Baldor Electric Company. "Product Information Packet: M3610T-57." n.d. Baldor Electric Company. 17 September < "Electric motors price India." n.d. 17 September GotTransmissions.com. "Buy Transmissions: Planetary Transmissions and Gearboxes for sale." n.d. GotTransmissions.com. 23 September < Igoe, Tom. "Basic Machines 2: Joints and Linkages." Tigoe.net. 17 September < Orientalmotor. "Stepper Motor Glossary of Terms." n.d. Orientalmotor. 17 September < Pearson Education. "Engineering Grapyics Glossary." n.d. Prentic Hall's ENGINEERING GRAPHICS. 17 September < Power Engineering & Manufacturing, Ltd. "Warranty-Terms & Conditions." 19 November Power Engineering & Manufacturing, Ltd. 17 September < Sowizral, Henry, Dave Nadeau and Mike Bailey. "Building 3D Shapes: Gear Train Example." 3&9 June Introduction to Programming with Java 3D. 17 September < Transdrive Engineering Services Ltd. "AC Motor Teco 1.1kW 4 Pole (1500rpm) LVED, IE2, B14 Face Mounted, Aluminium Construction, Frame Size D90S." n.d. transdriveonline. 17 September < 9